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1500-UM055_-EN-P - Rockwell Automation

1. 2400V 6900V 30 50 60Hz Isolating Switch L1 L2 L3 GRD S Door Interlock eee T o Fi alk i H H A owe o wee 1 o FA Current Limiting M ta Power Fuses Current Limiting Primary Fuses aE ft aN cer qH H2 Y 3 yF w San o j of 3 59 X1 X3 X2 0X4 Overload v 4 4 5 120 V ISa 4 Off Normal f 7 5 Test mi 0 a Test Supply Point fe 10 TS 11 12 th lh aw ae aly F3 MOV 2 M M TOV ob 1 CR isa CRI CR y CR 47g CRE pgg CR2 19 7 D 20 HHHH H aY gt Main Contactor M i REC MOV CC Closing Coil iT N HC Holding Coil t lt B Y Extra Auxiliary Contacts AMB GMH 32 33 N 7 Economizing o 0 Contactor CR2 gg KML y St Start a lt gt OP Oa 2 ae ke gt Main Contactor o o RI N Pilot Relay CR1 E CRI LEGEND Customer wiring a EMA a O Run Low voltage door mounted device heh lt gt 5 m Remove jumper when connecting remote equipment i Me 8 D cy Off IEEE number for protective device XP cA A Remote equipment 52 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Common Installation Chapter 4 2400V 6900V 30 50 60Hz uo 2 L3 S Figure 44 Typical Wiring Diagram Electrically Held Vacuum Contactor with IntelliVAC Control Isolating Switch Door Interlock FA T2 FA MTR g
2. End Cover Plate 92 Rockwell Automation Publication 1500 UMO55H EN P February 2015 ArcShield Plenum Installation Instructions Appendix B The End Cover Plate must be mounted on the closed end of the Line up at this time during the assembly using 5 16 in hardware see Figure 82 Left side STEP 4 Closing the Front of After the first stage of the Plenum assemblies have been mounted the Plenums the Plenum Sections can then be closed up by replacing the front duct sections as shown in Figure 83 Figure 83 Plenum Sections A f f IMPORTANT Do not re install the front duct section of the last Plenum on the exhaust side of the Line up at this time refer to STEP 6 Mounting Extension Elbow to Plenum Line up on page 94 for more information TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place STEP 5 Extension and Elbow The 36 Extension components and 90 Elbow Section are to be attached using Assem bly 5 16 in hardware in the following sequence Step 5A See Figure 84 Step 5B See Figure 85 Step 5C See Figure 86 TIP The Screen Cover Plate is attached in Figure 85 Rockwell Automation Publication 1500 UM055H EN P February 2015 93 Appendix Bs ArcShield Plenum Installation Instructions Figure 84 90 Elbow Section Assembly Step 5A Front View Figure 85 90 Elbow Section Assembly S
3. Current Limiting Power Fuses Current Limiting Primary Fuses m a m off Normal Test ox Overload ISb 0 6 0 Test Supply Point BAN 10 11 9 rh lo 120V 50 60Hz MV EC 4 TCO 7 AUX 2 0A 14A F7 Main Contactor M E Rockwell Automation Publication 1500 UM055H EN P February 2015 42 44 46 47 Extra Auxiliary Contacts pa GMM ag o P RNE ge o LEGEND Customer Wiring Low voltage door mounting device Remove jumper when connecting remote equipment IEEE number for protective device Remote Equipment gt Om IntelliVAC Notes AUX cco EC MeV TCO IntelliVAC module trip coil output Output relay contacts shown without control power applied Factory installed configuration power up states in effect are Contactor Status Fail Safe Module Status Fail Safe IntelliVAC to be programmed configured by the customer before start up IntelliVAC module vacuum contactor auxiliary input IntelliVAC module closing coil output IntelliVAC module external capacitor input Main contactor I
4. Figure 64 Auxiliary Contact Orientation EN D head Fastener KU CATALOG NO Lo 700 CPM Incorrect Rockwell Automation Publication 1500 UM055H EN P February 2015 73 Chapter5 Maintenance Isolation Switch Auxiliary The auxiliary contacts are mounted on the left side of the isolation switch Contacts slightly below the cams on the isolation switch shaft Normally open contacts Isolation Switch a Contacts ISa are on the outside of the isolation switch housing and normally closed contacts Isolation Switch b Contacts ISb are on the inside of the housing Figure 65 Location of ISa and ISb Auxiliary Contacts ISa Auxiliary ISb Auxiliary Contacts N C Contacts N 0 ISa and ISb contacts are exactly the same 700 CPM The cam controls the normally open or normally closed status of the contacts Refer to Figure 43 on page 52 to Figure 44 on page 53 for wiring diagrams IMPORTANT The Isolation Switch Ground Adjustment procedure refer to Isolation Switch Mechanism Grounding Adjustment on page 72 must be completed before adjusting the auxiliary contacts to ensure proper synchronization of the assembly Adjusting the Normally Open ISa Contacts Lock out Procedure on page 57 before working on the equipment Verify with a hot stick appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid sho
5. Remove self tapping screws ADANGER equipment Failure to do so will defeat the structure s arc resistant capabilities and result in electrical faults and cause damage to equipment or serious injury to personnel i ATTENTION Ensure all barriers are replaced before re energizing the Front Access Bottom Exiting Load Cables If the cables in your cabinet exit from the bottom the procedure to access the power bus is almost identical to the one above Follow the procedure for Front Access Top Exiting Load Cables but remove the cable duct barrier and cable duct boot from the top of the lower power cell rather than those at the bottom see Figure 34 Rockwell Automation Publication 1500 UMO55H EN P February 2015 39 Chapter3 Installation Arc Resistant Enclosure ArcShield Figure 34 Bottom Cable Exit Configuration Cable Duct Barrier Cable Duct Boot Load Cable Connections Lock out Procedure on page 57 of Chapter 5 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power refer to Power IMPORTANT The current transformers may be positioned for top or bottom cable exit Follow the appropriate procedure described for your starter configuration IMPORTANT _ ForArcShield units cable size should not exc
6. Standard Enclosure 3 Open the low voltage cell doors refer to Opening the Low Voltage Doors on page 13 4 Disconnect the control wiring harness from the wire plug at the lower left side of the contactor 5 Remove the two self tapping screws from the center vertical channel see Figure 10 6 Pull on the center vertical channel to swing out the low voltage panel Figure 10 Center Vertical Channel Remove self tapping screws from center vertical channel Control Wiring Harness 20 Rockwell Automation Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 7 Remove each glass polyester barrier located in front of the current transformers see Figure 11 Figure 11 Removing Glass polyester Barrier i j Current Transformers Remove self tapping screws from barrier assembly Glass polyester barrier 8 Remove the retaining screw from the cable duct barrier and remove the barrier see Figure 12 9 Remove the two retaining screws from the cable duct boot and remove the boot see Figure 12 Rockwell Automation Publication 1500 UM055H EN P December 2014 21 Chapter2 Installation Standard Enclosure Figure 12 Removing Cable Duct Boot and Barrier Current Transformers CT Mounting Plate Loosen Retaining Screws Cable Duct Boot Remove Retaining Screws Cable Duct Barrier 10 To access the left side of the power bus locate the two bus a
7. Standard Enclosure 3 Once the rear bus cover is removed you will see the three power bus bars and the ground bus bar see Figure 8 Figure 7 Access to Power Bus from Side and Rear of Cabinet Center Rear Bus Access Cover Side Bus Access Cover Figure 8 Bus Bars from Back Access 18 Rockwell Automation Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 Side Access A side bus access cover is located on each side of the controller 1 Remove the hardware from the appropriate side bus access cover see Figure 7 2 Remove the side bus access cover 3 Once the side bus access cover is removed you will see the three power bus bars and the ground bus see Figure 9 Figure 9 Side Bus Access Cover Removed Front Access Access to Power Bus Lock out Procedure on page 57 of Chapter 5 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power refer to Power 1 Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 of Chapter 5 for both medium voltage power cells and the power bus 2 Open the doors and remove the hinge pins Rockwell Automation Publication 1500 UM055H EN P December 2014 19 Chapter2 Installation
8. 8 Nem 6 lb ft 5 16 in hardware 15 Nem 12 Ibeft 3 8 in hardware 27 Nem 20 lb ft 1 2 in hardware 65 Nem 48 Ibeft Rockwell Automation Publication 1500 UM055H EN P February 2015 55 Chapter5 Maintenance Door Interlock Circumvention medium voltage cell while the unit is energized When the unit is in operation do not circumvent this interlocking safety feature Always disconnect and lock out incoming power refer to Power Lock out Procedure on page 57 before proceeding with any adjustments requiring the handle to be moved to the ON closed position Failure to do so may result in electric shock causing severe burns injury or death i ATTENTION The door interlock mechanism is designed to prevent access to the Some of the following sections may require moving the isolation switch handle to the ON position while the medium voltage door is open The interlocking safeguards in the mechanism are designed to prevent the handle from moving to the ON position while the cabinet door is open e To circumvent this safety feature use a screwdriver or other tool to depress the door interlock lever in a downward movement e Hold the lever down while moving the handle to the ON closed position Figure 45 Door Interlock Lever Door Interlock Lever ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death 56 Rockwell
9. Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 ATTENTION Always perform the Power Lock out procedure before servicing the equipment Failure to do so may result in severe burns injury or death Power Lock out Procedure handle to the ON position To avoid shock hazards disconnect and lock out ATTENTION The following procedure requires moving the isolation switch incoming power before proceeding with servicing the equipment Failure to lock out incoming power will result in a live power cell once the isolation switch handle is in the ON position and may cause severe burns injury or death Rockwell Automation does not assume any responsibility for injuries to personnel who have not completed the following safety procedure prior to servicing the equipment 1 Disconnect and lock out all feeder power supplies to the starter 2 Move the isolation switch handle to the OFF position 3 Ifthe unit is equipped with power factor correction capacitors stored energy must be dissipated before entering the power cell Wait at least five minutes before entering the power cell or dissipate the power using the following procedure a Verify that the isolation switch handle is in the OFF position b Open the low voltage door c Connect the appropriate power supply 120 or 230V into the auxiliary control power circuit as shown on the electrical drawing see Figure 46 d Move the control switch to the TEST
10. Cables entl chvion te cuit eas us betas 27 Bottom Exiting Load Cables nos tavgcsatnsevbbewevvnesacatines 28 Chapter 3 Door Opening Procedite vis socncetaseneneletve tear see coke nemens 29 Opening the Low Voltage Doots 2 50s a05 sass eand ees aewes 29 Opening the Medium Voltage Doors 000 eee e eee eee 30 OCNOLING Sacer od hei aud beauties ease Eee e e EE Shes 31 Joining Sections moa ea aa Snr ipeara ee te eda iA tea ee carers 32 Access to the Power Bus codices Pets ee et Si Re ter a 33 Reat ACCESS ea n a ceases te Sevssith nig bd Saeco eases 34 Side ACCESS culeh te CR eke UM bowed CAL Miele bias Mh oh 34 Front Access Access to Power Bus 0 ccc eeene ee eenees 36 Front Access Bottom Exiting Load Cables 0 6 39 Load Cable Connections nsickiaieidd ue ea hs 40 Top Exiting Load Cables A st cuswanecocegta ds Seer ahaleovny dicen 41 Bottom Exiting Load Cables Sac cncuenkesesddaseeseohanmers 42 Chapter 4 B s Splici g sabes dita kG a ie ids eye grate RU E AE AA 45 Power Biise eset alt uE Soller i ik tat ok ee os ae 45 Rockwell Automation Publication 1500 UM055H EN P February 2015 5 Table of Contents Maintenance Spare Parts ArcShield Unit Information Insulated Power Bus Splicing 0c cece eee e cece eens 46 Gro nd Buss cnr otek atte te hc tena eae EEE a 47 Incoming Line Cable Connections 54h ink taceieuna eevee ales 47 Installation of Current Transformer Barti rii4s
11. IntelliVAC Electrically Held and Mechanical Latch 1 1503VC BMC5 EM1 IntelliVAC Plus Electrically Held and Mechanical Latch 6 80174 902 14 R Internal IntelliVAC fuse 6 3A 250 V Littlefuse 21506 3 1 Engineering Data Power Fuses 3 Engineering Data Primary Fuses CPT PT 2 Engineering Data LV Control Circuit Fuses 2 Engineering Data Heater Elements if used 3 40266 515 03 20 Amp Isolation Switch Auxiliary Contact Cartridge 700 CPM 2 80178 707 53 Isolation Switch Refurbishment Kit Series R or higher 1 80158 357 51 Nyogel 759G Lubricant 3 RU 8216 Dow Corning 55 O ring Lubricant 1 80144 491 02 Fuse Extractor For clip on fuses only 1 1 Consult spare parts list in service manuals that are provided following delivery of equipment 2 The following is included with the LV Control Panel CR1 relay CR2 relay rectifier MOV assembly test switch test plug Note For mechanical latch assemblies an additional CR1 relay is substituted for the CR2 relay 3 For starters with IntelliVAC control 4 Power fuses are R rated for motor loads or E rated for non motor loads Power fuses are sized to the motor or transformer load data provided at the time the starter is ordered Refer to dimensional drawings for specific fuse type and size Bolt on or clip on fuses are available for various load sizes Contact Rockwell Automation for details 5 For starters with electro mechanical control 6 For starters wit
12. To install the replacement fuse place the fuse between the fuse clips Rockwell Automation Publication 1500 UM055H EN P February 2015 61 Chapter5 Maintenance 6 Ensure that the flares on the fuse ferrules are properly located with respect to the fuse clips 7 Apply a rapid shove to the bottom portion of the fuse barrel to force the fuse into the clip 8 Apply a rapid shove to the top portion of the fuse barrel to force the fuse into the clip 9 Grip center of fuse barrel with both hands and apply slight back and forward force to ensure fuse has been properly seated in the fuse clips 10 Again check and verify that the flares at the top and bottom of the fuse are not in the contact area of the fuse clip 11 Ifinterphase barriers were previously removed ensure they are properly reinstalled Figure 51 Clip on Style Medium Voltage Power Fuse Blown Fuse Indicator shown in blown state Flares Contactor Maintenance Refer to publication 1502 UM050_ EN P or 1502 UM052_ EN P for contactor maintenance instructions Removing the Contactor Lock out Procedure on page 57 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power refer to Power 1 Complete the Power Lock out Procedure refer to Power Lock out P
13. for standard cabinet only 1 Electrically open the contactor by pressing the STOP button on the starter or at the remote control location Move the isolation switch handle to the OFF position see Figure 22 Unbolt the door locking bolts for medium voltage door The door is now released and will swing open A ob Bw N Reverse the procedure to close the door Door lock bolts must be adequately tightened refer to Recommended Torque Values on page 11 of Chapter 1 for torque values IMPORTANT When closing the medium voltage door ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange Do not overtighten the bolts If the door is not securely fastened it will not be possible to move the isolation switch handle to the ON position 30 Rockwell Automation Publication 1500 UM055H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 TIP On all ArcShield starters the sticker in Figure 22 is attached to each door for your reference Figure 22 Label on Arc Resistant Door 73 2 a o POUR OUVRIR TO OPEN 4 MANETTE DU 4 ISOLATION SWITCH SECTIONNEUR SI HANDLE F PROVIDED EXISTANTE ALA IN OFF POSITION 1 POSITION HORS CIRCUIT 2 LATCH HANDLE IN S 2 VERROUILLEZEN OPEN POSITION POSITION D OUVERTURE 3 LOOSEN BOLTS AT 2 3 DESSERRE ZLES PLACES 3
14. injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies New and Updated Information This manual contains new and updated information Summary of Changes This table contains the changes made to this revision Topic Page Replaced inside front cover Inside Front Cover Replaced Typical Structure and Typical Nameplate graphics 10 Added Environmental Conditions 11 Replaced Center Vertical Channel graphic 20 Updated procedure for Opening the Medium Voltage Doors 30 Added step to procedure for Joining Sections 32 Added information to Attention table 39 Added information to Attention table 42 Added information to Attention table 43 Replaced Typical Ground Bus Splicing Configuration graphic 47 Updated Isolation Switch Kit and stocking quantity 79 Added Series R or higher to 80158 707 53 79 Added Attention table 90 Added instructions to Cabinet preparation 90 Added Attention table 99 Added instructions to Cabinet preparation 99 Rockwell Automation Publication 1500 UM055H EN P February 2015 Summary of Changes Notes 4 Rockwell Automat
15. opening see Figure 36 Rockwell Automation Publication 1500 UM055H EN P February 2015 41 Chapter3 Installation Arc Resistant Enclosure ArcShield Figure 36 Load Cable Conduit Openings ee Load Cable Conduit Opening for Top of Cabinet IA AN Cables from Top Power Cell pa eh Load Cable Conduit Opening for Cables from Bottom Power Cell Current Transformer Mounting Plate 7 Connect the cables to the current transformers and tighten the connections to 65 Nem 48 lbeft 8 Connect cable shields to the ground lug 9 Reinstall the cable duct boot and reassemble the cabinet equipment Failure to do so will defeat the structure s arc resistant capabilities and result in electrical faults and cause damage to equipment or serious injury to personnel ATTENTION Ensure all barriers are replaced before re energizing the Bottom Exiting Load Cables TIP Follow steps 1 4 from previous section 5 Load cables for the top power cell should be routed first Pull the cables into the cabinet through the appropriate opening see Figure 37 Run the cables behind the current transformer mounting plate and into the top power cell 42 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 Figure 37 Load Cable Conduit Openings e Load Cable Conduit Opening for cables from top power cel
16. position Figure 46 Control Panel IntelliVAC Control Control Switch Auxiliary Power Receptacle Rockwell Automation Publication 1500 UM055H EN P February 2015 57 Chapter5 Maintenance e Electrically operate the contactor by pushing the START button on the unit or at a remote location f Disengage the contactor and move the control switch to the OFF position Disconnect the external power supply g Complete the Power Lock out procedure 4 Open the medium voltage door 5 Visually inspect that the isolation switch blades fully engage the grounding pins on the grounding bar The isolation switch shutters should be closed see Figure 47 Figure 47 Inspecting Isolation Switch in Open Position See Detail A Grounding Bar Isolation Switch Blades must fully engage Grounding Pins of Grounding bar Verify for each phase Isolation Switch Shutters must be closed Verify for each phase Isolation Switch Blades in open position Viewed from back with components removed for clarification 58 Rockwell Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 6 Check the line and load sides of the contactor with a hot stick or appropriate voltage measuring device for the system voltage to verify that they are voltage free see Figure 48 a Check for line side voltage at the top vacuum bottle terminals b Check for load side voltage at the bottom vacuum bottl
17. structure series numbers on the splice kit package match the structure series number found on the cabinet nameplate refer to Starter Identification on page 9 of Chapter 1 for details regarding the nameplate 2 Refer to Access to the Power Bus on page 33 of Chapter 3 for either standard or ArcShield enclosure 3 For a 12004A power bus assemble the splice bars as shown in Figure 38 Tighten the nuts to 65 Nem 48 lbeft For a 2000A power bus assemble the splice bars as shown in Figure 39 Tighten the nuts to 65 Nem 48 lbeft IMPORTANT Attach the bus links to the cabinet on the left side first as viewed from the front of the unit IMPORTANT Always place the bus clamps on the rear side of each main horizontal bus or splice bar as viewed from the front of the unit Rockwell Automation Publication 1500 UM055H EN P February 2015 45 Chapter 4 46 Common Installation Figure 38 Typical 1200A Power Bus Splicing Configuration Viewed from front of cabinet Bus Support Bus Clamp 4 2a gt x D o gt o 7 Main Horizontal oe Flat Washer Power Bus Hex Nut Lock Washer Figure 39 Typical 2000A Power Bus Splicing Configuration Viewed from front of cabinet Power Bus Splice Bar Bus Clamp P B Main Horizontal spe Bats Power Bus Hex Nut Flat Washer Lock Washer equipment Failure to do so may result in electrical faults and cause damage to f ATTENTION Ensure all barriers
18. type unit ratings and bus ratings 1 Not available on arc resistant designs Chapter1 General Information Figure 1 Typical Structure Nameplate HIGH VOLTAGE cise INDUSTRIAL CONTROL C ee u s EQUIPMENT sieves 63YL SERIES NO 17x 1 72 BLANK STRUCTURE SERIES 17 x 58 BLANK 17 x 32 TYPE BLANK SECTION 17 x 32 17 x 32 STRUCTURE BLANK IEC TYPE BLANK O BUS RATINGS VAL NOM DES BARRES OMNIBUS Q AT x 36 AT x24 V MAX 3PH BLANK AMPS Blank Hz 130kA PEAK 50kA 0 5sec GROUND BUS SIZE GROSSEUR DE LA BARRE M A L T 375 X 2 00 UNIT RATINGS VAL NOM DES UNITES UNIT NO 4X6 x86 AMPS MAX UNIT NO 17 x 36 17 x 36 BLANK BLANK AMPS MAX TOTAL STRUCTURE 17 x 36 STRUCTURE ENTIERE BLANK AMPS MAX MADE IN CANADA FABRIQU AU CANADA y A unit nameplate is also found in the low voltage compartment with specific unit motor application information see Figure 2 Figure 2 Typical Unit Nameplate HIGH VOLTAGE INDUSTRIAL CONTROL EQUIPMENT QUIPEMENT DE CONTR LE INDUSTRIEL HAUTE TENSION UNIT SERIES S RIE DE UNITE E102991 QC cObus LISTED 63YL DIMENSION DIAGRAM SCHEMA DES DIMENSIONS CATALOG NO N DE CATALOGUE ELECTRICAL DIAGRAM SCHEMA ELECTRIQUE RATING CARACTERISTIQUES Vv A Hz PH BIL 3 v A H
19. 1ds sess ncstaneiees 49 Hi Pot and Megger Wests cs cas eas pees een ancadydh oon pene 49 Start up Procedure ihe doe echigsal inde tae EA EE 50 Contactor Inspection 64 s batiiowces sy ewekee ae Shut gaate ey dale 50 Preliminary Checksicic 3 ue 8c Fo aang ele dieenes a5 ox 50 Testing Contactor Operationins s 0 lt 5 x 9he Vag eiskensseeen point 51 Typical Wiring Didoramsevii ceases cohol ou ove eed te eee ual 52 Chapter 5 Tool Reguitementi nsss ataty ated cok aE a ree neha 55 Recommended Torque Valves oei2 24 020 icc teeta ek usu hoaees 55 Door Interlock Circumvention s lt s cccvesdeliaasabiuds oenveakaumennss 56 Power Lock out Procedure n neneeese ereenn 57 Fuse Removal and Replacement 24 5 32i0 dices tae toueas tee ee 60 Bolt on Fuse Removal Installation 0 2 ce eee eee eee 61 Clip on Fuse Removal Installation 0 cece seen ee eee 61 Contactor Maintenance ais pstergscndan yA pens vise Se Rser een paeeS 62 Removing the Contactos vsdadscereerhs ieuck idee eee aens beeuls 62 Contactor Interlock Rod Adjustment 0 0 00 cece ee ee eae 64 To Reduce the Gap Distance y2222 c cudean ches eratur ve aedianmes 65 To Increase the Gap Distance 3 ics tiie ve iedecd oer eniendd hee 65 Isolation Switch Mechanism Inspection and Lubrication 67 Isolation Blade Switch Adjustment 0 ssnkes wasieesaedes weenie 69 Isolation Switch Mechanism Grounding Adjustment 72 Auxiliary Contacts Inspect
20. 2887 4788 Fax 852 2508 1846 Publication 1500 UM055H EN P February 2015 Supersedes Publication 1500 UM055G EN P May 2013 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in Canada
21. Contactor Interlock Rod Nylon Contactor Bushing Retaining Screw Nylon Contactor Bushing Nyloc Nut Contactor Operating Lever Contactor a Remaining Tabs 8 Remove the two contactor mounting bolts at the front of the contactor Rockwell Automation Publication 1500 UM055H EN P February 2015 63 Chapter5 Maintenance Contactor Interlock Rod Adjustment 64 9 10 11 12 13 Slide the contactor forward slightly to disengage the retaining tabs at the rear of the contactor from the mounting bracket inside the cabinet Carefully remove the contactor from the cabinet may be required to safely remove it from the cabinet and transport it Failure to use caution when moving the contactor may result in equipment damage and or personal injury i ATTENTION The contactor weighs approximately 22 kg 50 Ibs and assistance If the contactor is being replaced with a new one move the contactor interlock lever to the new contactor isolation switch It is very important to ensure this screw is replaced during reassembly i ATTENTION The retaining screw is critical to the mechanical integrity of the Reverse the procedure to reinstall the contactor Ensure the mounting bolts power cable hardware and bus bar hardware is properly torqued refer to Recommended Torque Values on page 11 of Chapter 1 Adjust the contactor interlock rod according to the Contactor Interlock Rod Adjustment procedure refer to Contac
22. LV in Figure 3 1 To access the compartments for standard cabinets use a flat head screwdriver and turn both of the 1 4 turn fasteners at least 90 in a counterclockwise direction 2 The door is now released and will swing open 3 Reverse the procedure to secure the doors Figure 3 Access to Low Voltage Compartments 1 4 turn fasteners for LV MV Upper Low Voltage Door 1 4 turn fasteners for Lower Low Voltage Door LV MV Rockwell Automation Publication 1500 UM055H EN P December 2014 13 Chapter2 Installation Standard Enclosure Opening the Medium Voltage Doors low voltage panel standard cabinets only Complete the Power Lock out procedure refer to Power Lock out Procedure on page 57 of Chapter 5 before attempting to open the swing out low voltage panel Failure to do so may result in severe burns injury or death i ATTENTION Medium voltage components are located behind the swing out Procedure on page 57 of Chapter 5 before beginning any service procedures to the unit Failure to do so may result in severe burns injury or death f ATTENTION Complete the Power Lock out procedure refer to Power Lock out Medium voltage doors are identified as MV in Figure 4 Figure 4 Access to Medium Voltage Compartments Door Locking Bolts for Upper LV Medium Voltage Door Isolation Switch Handles Door Locking Bolts for Upper LV MV Medium Voltage Door IMPORTANT Each medium voltage door has i
23. N To avoid shock hazards lock out incoming power refer to Power 1 Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 2 Open the medium voltage door 3 Inspect the condition of the clevis pin and cotter pins shown in Figure 57 Replace any worn parts 4 Ifit is necessary to replace the isolation switch operating lever or the interlock lever apply Dow Corning 55 O ring lubricant Rockwell Automation part no RU 8216 or equivalent to the pivot points before installing the new components see Figure 57 Rockwell Automation Publication 1500 UM055H EN P February 2015 67 Chapter5 Maintenance Figure 57 Isolation Switch Handle Mechanism Lubrication Points Threaded Connecting Rod Clevis Pins and Cotter Pins Isolation Switch Interlock Lever Lubrication Points at replacement only 5 Inspect the mounting hardware on the isolation switch operating lever and contactor interlock rod see Figure 57 Tighten any loose hardware 6 Inspect the isolation switch blades and the incoming line stabs see Figure 63 The mating surfaces must be clean and well lubricated 7 Remove any dirt and dried grease IMPORTANT Donot scrape or file the parts This may remove the plating and expose the underlying copper to corrosion 8 Lubricate the isolation switch blades and the isolation switch blade pivot points with Nyogel 759G
24. NOTES FOR SEISMIC APPLICATIONS e For installations on concrete the minimum depth and radius of concrete supporting the cabinet anchors is dependent on seismic loads Refer to important information above e For installations ona metal structure the metal plate depth and cabinet anchoring method is dependent on seismic loads Joining Sections TIP Joining hardware can be found in a package mounted to the front of the shipping skid TIP Refer to publication MV 0S050_ EN P for level floor surface requirements 1 Position the left side section on a level surface and secure the section in place with M12 1 2 in floor mounting bolts refer to Anchoring on page 31 2 When joining ArcShield sections apply a continuous 3 mm 1 8 in wide bead of silicone sealer around the perimeter of one section 3 Remove the side bus access covers if applicable 32 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 4 Position the right section against the left section Ensure that the surface is level 5 Secure the sections together using the 1 4 20 self tapping screws Thread the screw through the 7 mm 0 281 in clearance hole to the corresponding 6 mm 0 219 in pilot hole To access the front clearance holes of the left side cabinet open the medium voltage doors To access the rear clearance holes remove the rear covers of the starter If rear access is not
25. User Manual Allen Bradley Medium Voltage Controllers 200 400A Two High Cabinet Standard and Arc Resistant Enclosure Publication 1500 UMO55H EN P Rockwell Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Roc
26. _ BOULONS DE PORTE A2 B PLACES e e B B 9 POUR FERMER o TO CLOSE zi A MANETTE DU A ISOLATION SWITCH er CHEE HANDLE F PROVIDED Bagh Ee ches IN OFF POSITION A als arenans B VISSEZ LES BOULONS 3 A DE PORTE 2 PLACES 10 BOLTS AT 2PLACES 10 lo pi 13 Nm MAXIMUM MAXIMUM DO NOTUSE NUTILISEZPASLES POER TOOLS QUTILS DE PUISSANCE B c VERROLILLEZEN B e EE 5 pex FERMETURE 0006 02 r 4 P P Anchori ng Place the controller in the desired installation location Use M12 1 2 in floor mounting bolts to securely fasten the controller to the mounting surface See Figure 23 as an example of the location of the mounting holes in the cabinet TIP Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan IMPORTANT Pre determined cabinets have been designed for Uniform Building Code UBC seismic zone 1 2A 2B 3 and 4 and IBC International Building Code seismic activity without overturning or lateral movement provided they are securely mounted according to UBC IBC and local building codes This can include concrete pad design steel floor design and the sizing of cabinet anchors Concrete floor cutouts must not be adjacent to floor anchor bolts and must be sized to seismic load Consult factory if floor mounting must be reviewed by an accredited engineer Many jurisdictions require an engineer from the local area to review the design Seismic qualification does not in
27. adequate space is provided around the plenum exhaust as outlined in Figure 71 through Figure 73 IMPORTANT Be aware that equipment in the area of the plenum exhaust point will be damaged or destroyed Rockwell Automation Publication 1500 UM055H EN P February 2015 83 AppendixA ArcShield Unit Information Figure 71 Plenum Exit Left with Extensions to Internal Controlled Access Area Top View vs Personnel Access Barrier Figure 72 Plenum Exit Left with Extension s to Internal Controlled Access Area Front View Personnel A Access Barrier AR 7 Minimum H 3 5 m 138 inches Minimum L 1 2 m 47 inches Minimum Volume of space required for safe pressure relief X Y H 11 m 390 cubic feet 84 Rockwell Automation Publication 1500 UMO55H EN P February 2015 ArcShield Unit Information Appendix A Figure 73 Chimney Exhaust Space Requirements H1 _ Minimum H1 1 7 m 67 inches Minimum H 1 m 39 inches Additional Notes e The walls of the plenum exit area must be capable of withstanding the pressure generated e Any painted surfaces which face direct contact with the arc products may ignite Flame suppression is recommended e The exit point can also be outside the building Ensure exit area can not be bl
28. are replaced before re energizing the equipment or severe injury to personnel Insulated Power Bus Splicing If the starter is equipped with insulated power bus then a splice kit with insulated links insulating boots and tape will be provided Refer to the kit for installation instructions Rockwell Automation Publication 1500 UM055H EN P February 2015 Common Installation Chapter 4 Ground Bus 1 See Figure 40 to determine the correct ground splice configuration and assemble as shown 2 Torque the hardware to 15 Nem 1 Nem 12 lbeft 1 lbeft 3 Check all hardware for correct tightness and replace all covers and plates Figure 40 Typical Ground Bus Splicing Configuration Front View Ground Bus Splice Bar Hex Nut Lock Washer Flat Washer Main Ground Bus gt O a oO oO oO Ground Bus Support gt jo equipment Failure to do so may result in electrical faults and cause damage to i ATTENTION Ensure all barriers are replaced before re energizing the equipment or severe injury to personnel Incoming Line Cable Connections Lock out Procedure on page 57 of Chapter 5 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death i ATTENTION To avoid shock hazards lock out incoming power refer to Power Incoming cables are connected to the power bus in the last s
29. ast Fastened at the opening of the last Connected at the exhaust end of the component on the exhaust end Plenum in the line up opposite the Plenum or Extension exhaust end to seal Plenum end General Plenum Layout for An example of a general Plenum assembly configuration is shown in Figure 76 ArcShield Lin e up Plenums of varying widths are mounted directly over the MV enclosures of the corresponding width A 0 9 m 36 in Exhaust extension assembly is shown mounted on the extreme right side Plenum of the equipment Line up can alternatively exhaust to the left 88 Rockwell Automation Publication 1500 UMO55H EN P February 2015 ArcShield Plenum Installation Instructions Appendix B f Figure 76 ArcShield Line up 36 in Exhaust extension Sealed end Exhaust end Plenum exhaust can be on the left or right hand end of the line up Pictures and figures in this procedure are shown for a right hand exhaust exit direction Also shown is an optional vertical top direction exhaust extension see Figure 88 IMPORTANT Plenum components not directly mounted to the tops of the MV enclosures must have additional mounting support This includes the Extension components and 90 Elbow Sections refer to STEP 7 Additional Mounting Support on page 96 STEP 1 Mounting a Single Before mounting a single Plenum over an MV enclosure the front duct
30. available refer to Front Access Access to Power Bus on page 19 of Chapter 2 When joining the ArcShield sections use the provided 1 4 20 thread fasteners to secure the perimeter of the horizontal bus opening ensure all bolts are installed Before joining sections together ensure there is a silicone seal around the bus bar opening 6 Secure the right section to the floor using M12 1 2 in floor mounting bolts refer to Anchoring on page 31 IMPORTANT To prevent arc gas from escaping all mounting holes on the sides and floor of the enclosure must have hardware installed Figure 24 Joining Sections Power Bus cutout holes must align Silicone is applied around power bus cutout area to prevent gas leakage between joined cabinets Access to the Power Bus ATTENTION This procedure requires contact with medium voltage rN components To avoid shock hazards lock out incoming power before working on the equipment refer to Power Lock out Procedure on page 57 of Chapter 5 Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death Rockwell Automation Publication 1500 UM055H EN P February 2015 33 Chapter3 Installation Arc Resistant Enclosure ArcShield Rear Access 1 Remove the hardware securing the center rear bus access cover see Figure 25 2 Remove the center rear bus access cover 3 Once the r
31. ccess covers at the rear left side of the power cell Remove the four self tapping screws from each cover and remove the covers see Figure 13 Figure 13 Removing Bus Access Covers Remove four self tapping screws from each Bus Access Cover 22 Rockwell Automation Publication 1500 UM055H EN P December 2014 11 12 13 14 Installation Standard Enclosure Chapter 2 If access to the right side of the power bus is required remove the vacuum contactor from the upper power cell refer to Removing the Contactor on age 62 of Chapter 5 Remove the power fuses from the isolation switch Remove the interphase barriers from the trailer fuse block by raising them vertically up and out of the mounting slots see Figure 14 Use a 9 16 in socket to remove the contactor bus bars from the isolation switch trainer fuse block Figure 14 Contactor Bus Bars Trailer Fuse Block for Clip on Fuses Shown 15 16 Trailer Fuse Block Contactor Bus Bars Disconnect the secondary control wiring from the control power transformer CPT and remove the CPT mounting plate Leave the CPT attached to the plate remove and transport the unit Use caution when removing the CPT Failure to do so may result in personal injury and or damage to the equipment i ATTENTION The CPT is heavy and assistance may be required to safely To access the right side of the power bus remove the self tapping screws from the lower gla
32. ck hazards lock out incoming power refer to Power 1 Move the isolation switch handle to the OFF open position 2 Loosen the bolt holding the outside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft 3 Move the isolation switch handle to the ON closed position and check that nothing prevents cam from rotating with the shaft 74 Rockwell Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 4 Insert a 6 35 mm 0 25 in diameter pin into the cam groove between the cam follower and the end of the cam groove Figure 66 Adjusting Auxiliary Contacts ISa Auxiliary Contact Shown Gap 0 25 in 6 35 mm Cam Cam Follower Auxiliary Contact 5 Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin 6 35 mm 0 25 in 6 Move the isolation switch handle to the OFF open position and check that nothing prevents the cam from rotating with the shaft 7 Tighten the bolt holding the cam to the shaft Move the isolation switch handle to the ON position and recheck the gap using the pin 8 Verify that auxiliary contact ISa is open when the isolation switch is open Verify that ISa contact is closed when isolation switch is closed Adjusting the Normally Closed ISb Contacts 1 Move the isolation swi
33. d for overall travel All three phases share the same main actuating shaft but the Phase 3 is the easiest to measure Figure 60 Isolation Switch Linkage Assembly Location Isolation Switch Linkage ome Assembly Phase 3 Wizz i play w T i i 4 Rest the customer supplied digital protractor on the bottom of the isolation switch linkage assembly The angle of the linkage must be 180 or slightly higher with a tolerance of 0 6 degrees TIP If a digital protractor is unavailable lay a straight edge against the bottom of the steel lever on the operating shaft to check for parallel alignment of the red link 70 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Isolation Switch Mechanical Threaded Linkage Maintenance Chapter 5 Figure 61 Isolation Switch Linkage Assembly Angle Location Must have tolerance of Shaft Assembly 0 6 degrees a 7 N AA SASL _ i Z ISRO NN gal f 1 VA ESS f R AR O INID DDO ic 7 A Red Glass pow fa H go Polyester i c Switch Link Air ez CZ2ZZZ22I2IZIZ2ZA ZILIA SS N3 SSS NY SN 5 Loosen the lock nuts at each clevis Note one is a left handed thread 6 Adjust the isolation switch mechanical threaded linkage with a wrench until the overall travel angle of the switch link is within the required tolerance 7 Hold the position of the threaded linkage and tighten the lock nuts F
34. dicate that the equipment will function properly after a seismic event ATTENTION Complete the Power Lock out procedure refer to Power Lock out Procedure on page 57 of Chapter 5 before beginning any service procedures to the unit Failure to do so may result in severe burns injury or death Rockwell Automation Publication 1500 UM055H EN P February 2015 31 Chapter3 Installation Arc Resistant Enclosure ArcShield Figure 23 Cabinet Floor Plan lt 13 05 331 4 7 50 191 lt gt 5 25 133 lt gt 4 88 124 K i 5 68 X 9 00 16 17 i IBA 2 144 X 229 9 32 237 30 00 762 pan 36 00 914 CB 5 68X 9 00 23 68 601 144 X 229 5 68 X 9 00 462 117 _ 288 X0 D 3 00 X 5 00 Y L 176 X 127 g i a 2 31 59 gt Me 31 38 797 gt lt x o gt Front Line cable conduit opening Mounting holes for 1 2 in M12 anchor bolts Load cable conduit opening for bottom compartment Mounting holes for 1 2 in M12 anchor bolts Load cable conduit opening for top required for seismic applications only compartment Minimum distance to concrete floor cut out Control wire conduit opening required for seismic applications Each opening provides access to top and 1 00 25 x 3 00 76 removable sill channels bottom compartments
35. dity exceeds 85 space heaters must be used to prevent condensation The equipment must be stored in a heated building having adequate air circulation rN WARNING The equipment should never be stored outside Rockwell Automation products are built using materials that comply with Class 1 Industrial Clean Air sulfur environments as defined in IEC Standard 60654 4 Operating Conditions for Industrial Process Measurement and Control Equipment and G1 as defined in ISO S71 04 1985 Environmental Conditions for Process Measurement and Control Systems Airborne Contaminants High Altitude Application The equipment shall operate at altitudes from 0 1000 m 0 3300 ft above sea level without derating For applications above 1000 m 3300 ft the maximum current and basic impulse levels BIL of the controllers shall be derated and vacuum contactors may be compensated for operation at the specified altitude see publication 1500 SRO20_ EN P Rockwell Automation Publication 1500 UM055H EN P February 2015 Chapter 2 Installation Standard Enclosure IMPORTANT For information on the installation site preparation see General Handling Procedures for MV Products Publication MV QS050_ EN P ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death Door Opening Procedure Opening the Low Voltage Doors Low voltage doors are identified as
36. e Conduit Opening for cables from top power cell Load Cable Conduit Opening for cables from bottom power cell Bottom of Cabinet 6 For the bottom power cell pull the cables into the cabinet through the appropriate opening see Figure 19 7 Connect the cables to the current transformers and tighten the connections to 65 Nem 48 lbeft 8 Connect cable shields to the ground lug 9 Reinstall the cable duct boot and reassemble the cabinet equipment Failure to do so may result in electrical faults and cause ATTENTION Ensure all barriers are replaced before re energizing the damage to equipment or serious injury to personnel 28 Rockwell Automation Publication 1500 UM055H EN P December 2014 Chapter 3 Installation Arc Resistant Enclosure ArcShield This installation section contains information on arc resistant styles of enclosures referred to in this manual as ArcShield IMPORTANT For information on the installation site preparation see Publication MV QS050_ EN P ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death Door Opening Procedure Opening the Low Voltage Doors Low voltage doors are identified as LV in Figure 17 on page 26 1 To access the compartments for ArcShield cabinets turn the release handle counter clockwise 90 2 The door is now released and will swing open 3 Rev
37. e fuse configuration will determine what length of extension will be required to get at the mounting hardware The fuse configuration will also determine what size of interphase barriers are installed the lower barriers can be removed to provide better access to the fuse mounting nuts 1 Remove the two lower mounting nuts lock and flat washers from the mounting studs 2 Remove the upper two mounting nuts lock and flat washers from the mounting studs and remove the fuse from the fuse mounting studs 3 Install the replacement fuse on the four mounting studs hold the fuse in place and install the upper two flat washers lock washers and nuts Torque nuts to 15 Nem 12 lbeft 4 Install the lower two flat washers lock washers and nuts Torque nuts to 15 Nem 12 lbeft 5 Ifinterphase barriers were previously removed ensure they are properly reinstalled Clip on Fuse Removal Installation Recommended tool Fuse extractor part 80144 491 02 optional TIP The interphase barriers located at the bottom of the fuse assembly can be removed to ease the removal and installation of the fuse 1 Place the cup section of the fuse extractor over the top of the fuse 2 Pull back on fuse extractor with a quick motion to dislodge the upper portion of the fuse from top fuse clip 3 Set fuse extractor aside 4 Remove the lower portion of the fuse from fuse clip by pulling up and slightly rotating the fuse in one entire movement 5
38. e isolation switch handle towards the OFF position and observe the point at which the movable isolation switch blades separate from the incoming line stabs The auxiliary contacts must change state from the closed to open position before the isolation switch blades lose contact with the incoming line stabs This prevents the isolation switch from being opened while the unit is energized and under load conditions opening the isolation switch under load conditions Improper adjustment may result in damage to the equipment and or severe burns injury or death to personnel ATTENTION The auxiliary contacts must be properly adjusted to avoid 4 If the auxiliaries do not change state before the isolation switch opens repeat the auxiliary contacts adjustment procedure refer to Auxiliary Contacts Inspection and Replacement on page 73 Emergency Circu mvention hae conti P H ET o aa z o ro Procedure for Power Cell prol i it access to the power ce w ile the isolation switch handle is in the ON Ent position and the isolation switch is closed ntry IMPORTANT The following procedure is intended to be used only when the isolation switch cannot be opened as described in the Door Opening Procedure for either standard or ArcShield enclosures 76 Rockwell Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 voltage components Whenever possible lock out incoming power before beginning this procedure If you are unable t
39. e terminals Figure 48 Contactor Voltage Checkpoints Check line side power here Check load side power here 7 Use the Door Interlock Circumvention procedure refer to Door Interlock Circumvention on page 56 to move the isolation switch handle to the ON position 8 Check the isolation switch blades with a hot stick or appropriate voltage measuring device for the system voltage to verify that they are voltage free see Figure 49 Figure 49 Isolation Switch Voltage Check Points Isolation Switch Blades must fully engage Incoming Line Stabs Check incoming line voltage here ey J ite AD rm 9 Once all power circuits are vated to be voltage free move the isolation switch handle back to the OFF position The unit is now safe to service Rockwell Automation Publication 1500 UM055H EN P February 2015 59 Chapter5 Maintenance Fuse Removal and Replacement 60 A ATTENTION Only personnel who have been trained and understand the Bulletin 1500 product line are to work on this equipment Suitable safety equipment and procedures are to be used at all times Figure 50 Medium Voltage Power Fuses S 4 A A Bolt on Fuses of S J D 0 SALTY Clip on Fuse Clip on Fuse Extractor NA S ATTENTION Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock b
40. e working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death i ATTENTION To avoid shock hazards lock out incoming power refer to Power 1 Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 of Chapter 5 for both Medium Voltage power cells and that power bar 2 Open medium voltage power cell door see Figure 29 Figure 29 ArcShield Power Cell Upper 3 Remove the retaining screw from the cable duct barrier and remove the barrier see Figure 30 4 Remove the two retaining screws from the cable duct boot and remove the boot see Figure 30 36 Rockwell Automation Publication 1500 UM055H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 Figure 30 Removing Cable Duct Boot and Barrier Current Transformers CT Mounting Plate Loosen Retaining Screws Cable Duct Boot Remove Retaining Screws Cable Duct Barrier 5 To access the left side of the power bus locate the two bus access covers at the rear left side of the power cell Remove the four self tapping screws from each cover and remove the covers see Figure 7 on page 18 Figure 31 Removing Bus Access Covers Remove Bus Access Cover Rockwell Automation Publication 1500 UM055H EN P February 2015 37 Chapter3 Installation Arc Resista
41. ear bus cover is removed you will see the three power bus bars and ground bus see Figure 27 Figure 25 Access to Power Bus from Side and Rear of Cabinet Side Bus Access Cover Center Rear Bus Access Cover Side Access A side bus access cover is located on each side of the controller 1 Remove the hardware from the appropriate side bus access cover 2 Remove the side bus access cover see Figure 25 3 ArcShield units at the end of a line up have a ground connection to the inner plate of the side bus access cover see Figure 26 to Figure 28 This connection must be maintained to ensure unit arc resistant performance 34 Rockwell Automation Publication 1500 UM055H EN P February 2015 Side Bus Access Cover Ground Connection Installation Arc Resistant Enclosure ArcShield Chapter 3 Figure 26 Side Bus Access Cover Warning Label CONNECTION TO CONNEXION ALA MISE A GROUND MUST BE LA TERRE DOIT ETRE MAINTAINED MAINTENUE FAILURE TO DO SO MAY RESULT IN LOSS OF ARC RESISTANT INTEGRITY LE NON RESPECT DE CET AVIS PEUT CAUSER UNE PERTE D INTEGRITE DE LA RESISTANCE AUX ARCS 30006 340 02 1 Figure 27 Side Bus Access Cover Ground Connection Removable Handle Rockwell Automation Publication 1500 UM055H EN P February 2015 35 Chapter3 Installation Arc Resistant Enclosure ArcShield Front Access Access to Power Bus Lock out Procedure on page 57 of Chapter 5 befor
42. ection on the left IMPORTANT For Non ArcShield units cable size should not exceed 1 750 MCM or 2 500 MCM per phase For ArcShield units cable size should not exceed 1 500 MCM or 2 4 0 per phase For larger cables an incoming line module must be used Rockwell Automation Publication 1500 UM055H EN P February 2015 47 Chapter4 Common Installation 1 Remove the center back plate or side plate to access the power bus If access to the rear of the unit is not possible refer to Access to the Power Bus on page 17 of Chapter 2 for either standard or ArcShield enclosures 2 Connect the incoming power lines to the power bus Torque to specifications refer to Recommended Torque Values on page 11 of Chapter 1 see Figure 41 Figure 41 Incoming Line Cable Connections Ground Bus Lug IMPORTANT _ Ifline cables require installation by front access complete the incoming line connection before installing load cables 3 Connect the ground wire to the ground bus lug 4 Connect any external control wires to the control panel terminal blocks in the low voltage compartment Refer to wiring diagram 48 Rockwell Automation Publication 1500 UM055H EN P February 2015 Common Installation Chapter 4 Installation of Current Figure 42 Current Transformer Barrier Transformer Barrier Current Barrier Transformer bs fi y LN vy KON rH AY P re energ
43. ed and inspect the position of the Z clip with respect to the handle pin 8 Set the Z clip so that it is just above the handle pin Do not set the Z clip more than 3 mm 0 125 in above the pin Open the door and tighten the screws 9 Close the door and move the handle to the ON position Verify that the handle pin overlaps the Z clip and prevents the door from opening 10 Move the handle to the OFF position and tighten the door locking bolts Installing Z clip with Isolation Switch Handle in the ON Position 11 Close the door and tighten the door locking bolts 12 Position the Z clip as shown in Figure 68 Ensure the handle pin overlaps the top portion of the Z clip 13 Use the self tapping screws to reattach the Z clip 14 Complete steps 5 10 at the earliest opportunity to confirm that the Z clip assembly is correctly installed 78 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Chapter 6 Bulletin 1512 and 1512BT Units Parts List Spare Parts The following list of spare parts is valid for typical Bulletin 1512 and 1512BT units Please contact your local Rockwell Automation office to ensure that the following part numbers are valid for your system Table 3 Spare Parts List Part Number Description Recommended Stocking Quantity 80154 991 59 LV Control Panel 2 5 Electrically Held 1 80154 991 61 LV Control Panel Mechanical Latch 1 1503VC BMC5
44. eed 1 500 MCM or 2 350 MCM per phase Note Refer to Dimensional Drawings provided with order documentation for additional details related to cabinet floor plans 1 Complete the Power Lock out procedure refer to Power Lock out Procedure on page 57 of Chapter 5 2 Follow steps 2 to 6 from Front Access Access to Power Bus on page 36 for the procedure to swing out the low voltage panel 3 Remove the cable duct boot at the top of the cabinet for top exiting load cables or remove the one at the bottom of the cabinet for bottom exiting load cables see Figure 35 40 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 Figure 35 Access to Load Cable Conduit Openings Bottom Exit Cable Connect Load Cables to Current Transformers Removable Cable Duct Boot to load cable conduit opening for cables exiting from bottom power cell 4 Remove the appropriate load cable conduit openings in the top or bottom of the cabinet see Figure 36 or Figure 37 Top Exiting Load Cables TIP Follow steps 1 4 from previous section 5 Load cables for the bottom power cell should be routed first Pull the cables into the cabinet through the appropriate opening see Figure 36 Run the cables behind the current transformer mounting plate and into the bottom power cell 6 For the top power cell pull the cables into the cabinet through the appropriate
45. erlock Lever a To Reduce the Gap Distance 5 Loosen the two screws in the stop bracket and move the stop bracket up against the interlock lever 6 With the feeler gauge positioned in the gap move the interlock lever and the stop bracket closer to the isolation switch operating lever to reduce the gap space Tighten the stop bracket screws 7 Tighten the nyloc nut until it is snug against the contactor interlock lever Do not overtighten the nyloc nut as it will move the interlock lever and reduce the gap Proceed to Step 11 To Increase the Gap Distance 8 Loosen the two screws in the stop bracket and move the stop bracket away from the interlock lever 9 Loosen the nyloc nut until the gap reaches the desired size Rockwell Automation Publication 1500 UM055H EN P February 2015 65 Chapter 5 66 Maintenance 10 11 12 13 Move the stop bracket until it just touches the interlock lever and tighten the screws Apply Loctite 290 or equivalent adhesive to the stop bracket screws and torque the screws to 8 Nem 6 lbeft Move the isolation switch handle to the ON position Manually close the contactor by attaching locking pliers to the contactor interlock lever and pushing down until the armature plate contacts the magnetic cores see Figure 55 Verify that the interlock lever overlaps the isolation switch operating lever by at least 3 mm 0 125 in see Figure 56 Figure 55 Closing Contactor Man
46. erse the procedure to secure the door Figure 20 Access to Low Voltage Compartments Chimney Plenum Upper Low Voltage P 7 i Door handle 7 Th LV MV i Lv MV D Upper Low Voltage m Door handle b bi i fl LV MV LV MV i Lower Low Voltage ia Lower Low Voltage Door handle Door handle Rockwell Automation Publication 1500 UM055H EN P February 2015 29 Chapter3 Installation Arc Resistant Enclosure ArcShield Opening the Medium Voltage Doors Procedure on page 57 of Chapter 5 before beginning any service procedures to the unit Failure to do so may result in severe burns injury or death i ATTENTION Complete the Power Lock out procedure refer to Power Lock out Medium voltage doors are identified as MV in Figure 21 Figure 21 Access to Medium Voltage Compartments Chimney Plenum Upper Low Voltage Door hande mn set Lv MV t Upper Low Voltage Door handle Lower Low Voltage Door handle gt i P Ot LV MV LV MV ft Lower Low Voltage Door handle IMPORTANT Each medium voltage door has its own isolation switch handle and interlocking safeguards Upper and lower power cells are separated by an isolation barrier Refer to Access to the Power Bus on page 33 for the procedure to open the swing out low voltage panel behind the low voltage door
47. h IntelliVAC Plus control For 400A contactor spare parts refer to publication 1502 UM050_ EN P or Publication 1502 UM052_ EN P Rockwell Automation Publication 1500 UM055H EN P February 2015 79 Chapter6 Spare Parts Notes 80 Rockwell Automation Publication 1500 UM055H EN P February 2015 Overview ArcShield Design Appendix A ArcShield Unit Information ArcShield units have a robust arc resistant enclosure design that has been tested per IEEE C37 20 7 2001 Each ArcShield structure was tested to withstand the effects of an arc flash at 40 kA for 0 5 seconds ArcShield units provide Type 2B Accessibility ArcShield units typically include a pressure relief vent on the roof of the structure some incoming units may not have a pressure relief vent if top cable entry is required Under arc flash conditions the pressure relief vent will open allowing hazardous flames and gases to exit the enclosure via the plenum The low voltage panel area is sealed to prevent flames and gases from entering however appropriate personal protective equipment PPE must be used whenever working on live circuits Refer to NFPA 70E or SA Z462 in North America ATTENTION To ensure Arc resistant integrity it is important to ensure that the following rules are followed e The pressure relief vent may not be tampered with and it is not to be used as a step e Noalterations can be made to the ArcShield structure e All co
48. igure 62 Isolation Switch Mechanical Threaded Linkage Rockwell Automation Publication 1500 UM055H EN P February 2015 71 Chapter5 Maintenance 8 Actuate the Isolation Switch handle to verify the travel angle If the angle is incorrect repeat steps 5 through 7 until desired travel angle is reached ATTENTION All three isolation switch linkage assemblies must meet the angle tolerance requirements Isolation Switch Mechanism Grounding Adjustment Lock out Procedure on page 57 before working on the equipment Verify with a hot stick or other appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power refer to Power 1 Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 2 Inspect the grounding of the isolation switch blades When the isolation switch handle is in the OFF position the isolation switch blades must fully engage the grounding pins and be within 1 5 mm 0 06 in of the ground bar see Figure 63 When the isolation switch handle is in the ON position the blades must fully engage the incoming line stabs Figure 63 Isolation Switch Grounding Adjustment Maximum Gap 0 06 in 1 5 mm between ground Bar and Isolation Switch in open position Isolation Switch Blade Incoming Line Stab 72 Rockwell Au
49. imney Exhaust Label DANGER A DANGER ARC FLASH HAZARD HAZARD D ARC ELECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L EVENT REGION ETRE AREAS TO BE INACCESSIBLE AUX PERSONNEL INACCESSIBLE TO PERSONNEL PENDANT QUE L QUIPEMENT WHILE EQUIPMENT ENERGIZED EST SOUS TENSION FREE OF OBSTRUCTIONS DEMUNI D OBSTRUCTIONS REFER TO USER MANUAL REFERER AU MANUEL SEVERE INJURY OR RISQUE DE BLESSURES DEATH MAY RESULT CORPORELLES GRAVES OU MEME LA MORT Rockwell Automation Publication 1500 UM055H EN P February 2015 97 AppendixC ArcShield Chimney Installation Instructions General Plenum Layout for et example a general eel eal a uaa is shown a TRE Chimneys of varying widths are mounted directly over the MV enclosures of the ArcShield Line up corresponding width Figure 90 ArcShield Line up with Arc Chimneys 98 Rockwell Automation Publication 1500 UM055H EN P February 2015 ArcShield Chimney Installation Instructions Appendix C Cabinet Preparation In preparation for mounting a chimney remove the cabinet lifting means slips of lifting angles The bolts retaining the lifting means must be replaced in the holes from where they came Failure to do this will remove the cabinets ability to properly control any arc gases After the lifting angles or clips are removed remove 1 4 20 fasteners from the Relief vent on the top of the MV enclosure reinstalled in the same holes Failure to replace this hardwa
50. ion Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 5 Secure the sections together using the 1 4 20 self tapping screws Thread the screw through the 7 mm 0 281 in clearance hole to the corresponding 6 mm 0 219 in pilot hole To access the front clearance holes of the left side cabinet open the medium voltage doors To access the rear clearance holes remove the rear covers of the starter If rear access is not available refer to Front Access Access to Power Bus on page 19 6 Secure the right section to the floor using M12 1 2 in floor mounting bolts refer to Anchoring on page 15 Figure 6 Joining Sections Side Bus Access Cover 0 281 Pilot Holes 5x 0 219 Pilot Holes 5x 0 219 Pilot Holes 3x 0 281 Pilot Holes 5x Access to the Power Bus components To avoid shock hazards lock out incoming power before working on the equipment refer to Power Lock out Procedure on page 57 of Chapter 5 Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTION This procedure requires contact with medium voltage Rear Access 1 Remove the hardware securing the center rear bus access cover see Figure 7 2 Remove the center rear bus access Cover Rockwell Automation Publication 1500 UM055H EN P December 2014 17 Chapter2 Installation
51. ion Publication 1500 UM055H EN P February 2015 General Information Installation Standard Enclosure Installation Arc Resistant Enclosure ArcShield Common Installation Table of Contents Chapter 1 Document Sc pessisrerr iorri rekawa nra PEIEE AEE EEREN E EPEE EDS 9 Starter Identification o y y e ean eek nl ieee R A 9 Prepared Spaces rean e E AE E EN EEE A S 11 Series N m ber aame PAW stonatien oina E wu a iara 11 Motor Datare ieaanasaes niea e A EE O A E 11 Starter EeatUreS evon it av ctohe ise senile eee deel we aren 11 Recommended Torque Valuessc 75 8 otac ae tcsedee tees ole tees 11 Environmental Conditions 0 cece cece eee c ence eeeenenees 11 High Altitude Application lt eit esbelcisa Caen aley oo ee steele s 12 Chapter 2 Door Opening Procedute iii cyatawantw yaw Suge eeseeeswene teed 13 Opening the Low Voltage Doots i 4 lt cuok eee ts ede aes lewis 13 Opening the Medium Voltage Doors 00 eee eee 14 ANCRONNE merten oian e aE got ohare nia Wise ec uate eit op sera 15 Joining Sections espe et sei Oe ei hee cette nd oh eta nena RR he 16 Access tothe Power BUSS sorarsa niati ea Sateen ewes Paes 17 RearAccess a ea a E oo E A E teats 17 Side Acces A e E a a O A AS 19 Front Access Access to Power Bus 00 c cece ene eeeenees 19 Front Access Bottom Exiting Load Cables 046 24 Load Cable Connections 44 24 cciaaes toat wane sb aaah oisiasematas 25 Top Exiting Load
52. ion and Replacement 00 73 Isolation Switch Auxiliary Contacts 0 0 cece eee een eee eee ee 74 Adjusting the Normally Open ISa Contacts 200 74 Adjusting the Normally Closed ISb Contacts 2 75 Adjusting the Change of State Point 0 e cee eee eae 76 Emergency Circumvention Procedure for Power Cell Entry 76 Installing Z clip with Isolation Switch Handle in the OFF Position 78 Installing Z clip with Isolation Switch Handle in the ON Position 78 Chapter 6 Bulletin 1512 and 1512BT Units Parts List 00000 79 Appendix A OVERVIEW nicest oe ee ose ao Spe meted eam eaten 81 ArcShield Designo set cia cen eileen witha Cg eck Ce a elo as oe ain Gytd deca 81 Exhaust Systems Chimney or Plenum Option 0 08 82 Plenum Information 0 e cece cece cence eeeeenaees 82 Plenum Exhaust Considerations 0c cece eee nenene 83 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Table of Contents Additional Notes yo arana ted ani hatin ete Dated anos 85 Chimney Information sii 42 s adiche ith seta ae ea heed 86 Chimney Exhaust Considerations i402 bhegeteueigeaciees 86 Appendix B ArcShield Plenum Installation Recommended Torque Values t 22 4015 be emaaeeetertinte tekely 87 Instructions Plenum Bracing A E AA oy eitayonreeanstapel gor Ge a satenar eysane aus tek arene tesenan Geet Gane iehalences 87 Genera
53. izing the equipment Failure to do so may result in electrical faults and i ATTENTION Ensure current transformer barrier is installed before cause damage to equipment or serious injury to personnel Hi Pot and Megger Test Insulation integrity should be checked before energizing medium voltage electrical equipment Use a high voltage AC insulation tester or a Megger for this test If a Megger is used a 5000 volt type is recommended ATTENTION Exercise caution when performing high voltage tests on the equipment Failure to do so may result in electric shock causing severe burns injury or death ATTENTION Disconnect power factor correction capacitors if so equipped before performing the Hi Pot test Failure to do so may result in personal injury or damage to the equipment See Power Lock out Procedure refer to Power Lock out Procedure on page 57 of Chapter 5 for information on dissipating any stored power in the capacitors gt gt Rockwell Automation Publication 1500 UM055H EN P February 2015 49 Chapter4 Common Installation Start up Procedure 50 ATTENTION Remove all primary fuses for the control power transformer and AN or the potential transformer Failure to do so may cause damage to the equipment during the Hi Pot test Insulation can be tested from phase to phase and from phase to ground The recommended level for AC Hi Pot testing is 2 X Vj 1 volts where Vy is the rated line to line voltage of the power sy
54. kwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe
55. l Plenum Layout for ArcShield Line up 0005 88 STEP 1 Mounting a Single Plenum o 2 50150600 sdverdasearworawaes 89 Cabinet Preparation tools tsp eee eeu ee eth eee CEEA 90 Plenum Placement on Structure 0ccce ccc ceececeeeeens 90 STEP 2 Alignment of Side by Side Plenums 91 STEP 3 Sequence of Final Assembly 2 002 eeeeeeee es 92 STEP 4 Closing the Front of the Plenum Sections 93 STEP 5 Extension and Elbow Assembly 0e seen eee 93 STEP 6 Mounting Extension Elbow to Plenum Line up 94 STEP 7 Additional Mounting Support cee eee 96 Appendix C ArcShield Chimney Installation Recommended Torque Values covcniuioniiy poavac sare eteccset behets 97 Instructions General Plenum Layout for ArcShield Line up 0005 98 Cabinet Preparation wii ols er dd ogee dad 99 Chimney Placement on Structure 25 10s ktewtweneanwericese 100 Rockwell Automation Publication 1500 UMO55H EN P February 2015 7 Table of Contents Notes 8 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Document Scope Starter Identification Rockwell Automation Publication 1500 UM055H EN P February 2015 Chapter 1 General Information This User Manual pertains to the Rockwell Automation Bulletin 1512B medium voltage controller The Bulletin 1512B structure includes provisions for two complete MV controller
56. l from behind the cable duct boot Load Cable Conduit Opening for cables from bottom power cell 6 For the bottom power cell pull the cables into the cabinet through the appropriate opening see Figure 37 7 Connect the cables to the current transformers and tighten the connections to 65 Nem 48 lbeft 8 Connect cable shields to the ground lug 9 Reinstall the cable duct boot and reassemble the cabinet equipment Failure to do so will defeat the structure s arc resistant capabilities and result in electrical faults and cause damage to equipment or serious injury to personnel ATTENTION Ensure all barriers are replaced before re energizing the Rockwell Automation Publication 1500 UM055H EN P February 2015 4 amp 3 Chapter3 Installation Arc Resistant Enclosure ArcShield Notes 44 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Chapter 4 Common Installation Bus Splicing Power Bus components To avoid shock hazards lock out incoming power before working on the equipment refer to Power Lock out Procedure on page 57 of Chapter 5 Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTION This procedure requires contact with medium voltage 1 The power and ground bus splice kit can be found in a package mounted to the front of the shipping skid IMPORTANT Verify that the
57. location Use M12 1 2 in floor mounting bolts to securely fasten the controller to the mounting surface See Figure 5 as an example of the location of the mounting holes in the cabinet TIP IMPORTANT Refer to Dimension Drawing provided with order documentation for additional details related to cabinet floor plan Pre determined cabinets have been designed for Uniform Building Code UBC seismic zone 1 2A 2B 3 and 4 and IBC International Building Code seismic activity without overturning or lateral movement provided they are securely mounted according to UBC IBC and local building codes This can include concrete pad design steel floor design and the sizing of cabinet anchors Concrete floor cutouts must not be adjacent to floor anchor bolts and must be sized to seismic load Consult factory if floor mounting must be reviewed by an accredited engineer Many jurisdictions require an engineer from the local area to review the design Seismic qualification does not indicate that the equipment will function properly after a seismic event Rockwell Automation Publication 1500 UM055H EN P December 2014 15 Chapter2 Installation Standard Enclosure Figure 5 Cabinet Floor Plan Line cable conduit opening A mM a Load cable conduit opening for bottom compartment x Ey R Load cable conduit opening for top compartment y D Control wire conduit opening Each opening provides access to top and bottom compar
58. mable material or vapors e Ensure that adequate space is provided around the chimney exhaust as outlined in Figure 73 86 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Recommended Torque Values Plenum Bracing Appendix B ArcShield Plenum Installation Instructions The following instructions are provided to ensure the proper installation and function of plenum components supplied with ArcShield enclosures Refer to Appendix A for additional information related to ArcShield plenums before attempting to follow these instructions 1 4 20 Thread Fasteners 7 5 Nem 6 lbeft 5 16 18 Thread Fasteners 14 Nem 11 Ibeft Bracing of the plenum must be able to withstand the dynamic forces of the arc fault as well as any other vibration or seismic effects associated with the installation Most of this force will be in the direction opposite to where the relief vent exits The amount of bracing will depend on how the plenum is supported at its exit as well as the distance from the end of the cabinets to the exit vent e A flange is available for installing hangers to support the plenum weight e The plenum extension has holes for mechanical support e Weight per unit length of Rockwell supplied plenum 28 kg m 19 lb ft e Installer is responsible for ensuring that the plenum extension has sufficient support to resist the effect of vibrations and seismic effects IMPORTANT _ Planthe location where the plenum
59. n on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility Ho
60. nelliVAC module 53 Chapter4 Common Installation Notes 54 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Chapter 5 Maintenance ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death IMPORTANT Establish a maintenance and inspection schedule for the equipment Annual servicing or every 20 000 operations whichever comes sooner is the minimum recommended Extreme operating conditions may warrant additional attention Tool Requirements IMPORTANT Some components of this product incorporate Imperial hardware Rockwell Automation recommends the use of the appropriate tools to successfully complete the maintenance procedures on these components If you cannot obtain such tools contact your area Rockwell Automation sales office for assistance e Torque wrench 0 65 Nem 0 48 lbeft e Sockets 3 8 in 7 16 in 9 16 in 3 4 in and 7 8 in e Ratchet handle and extension e Wrenches 7 16 in 1 2 in 9 16 in 3 4 in and 7 8 in e Feeler gauges 1 3 mm 0 050 in 2 mm 0 080 in 0 5 mm 0 020 in e Flat blade screwdriver e Nyogel 759G Lubricant Rockwell Automation part no 80158 357 51 Recommended Torque When reinstalling components or when reassembling the cabinet tighten the Values following bolt sizes to the specified torque values Table 2 Hardware Torque Values 1 4 in hardware
61. ng installation Plenum Placement on Structure Once the Plenum has been lifted in place directly over the relief vent shown in Figure 80 all 1 4 20 fasteners removed in Cabinet Preparation above are replaced to attach the Plenum to the top of the enclosure Use hand tools only 90 Rockwell Automation Publication 1500 UM055H EN P February 2015 ArcShield Plenum Installation Instructions Appendix B Figure 80 Plenum Placement Use recommended torque value for 1 4 20 fasteners TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place STEP 2 Alignment of Side Plenums mounted side by side must be fastened together through the aligning by Si de Plenums holes using 5 16 in supplied hardware see Figure 81 Rockwell Automation Publication 1500 UM055H EN P February 2015 91 Appendix B ArcShield Plenum Installation Instructions Figure 81 Aligning Side by Side Plenums IMPORTANT Any unused holes must be filled with thread forming screws i e Lifting Lug holes All Gaps must be sealed and filled with silicone STEP 3 Sequence of Final All Plenums in a Line up must be mounted to the top of each enclosure and to Assembl the Plenum directly beside it before the front duct sections are re attached see y Figure 77 Figure 82 Sequence of Final Assembly
62. nsion drawings for the starter Motor Data Provide the following motor data e Locked rotor current e Full load current e Maximum locked rotor time e Acceleration time e Motor service factor e Motor horsepower Starter Features Provide information regarding any special features required for the starter kit Indicate if these features are different from the motor control features in the existing complete power cell When reinstalling components or when reassembling the cabinet tighten the following bolt sizes to the specified torque values Table 1 Hardware Torque Values 1 4 in hardware 8 Nem 6 lb ft 5 16 in hardware 15 Nem 12 Ibeft 3 8 in hardware 27 Nem 20 Ibeft 1 2 in hardware 65 Nem 48 lb ft The controller must accept nominal plant power of 2400V 3300V 4200V 4800V 5500V 6600V 6900V 5 15 or 7200 0 15 3 phase 50 60 Hz 3 2 Not available on arc resistant cabinets Rockwell Automation Publication 1500 UM055H EN P February 2015 11 Chapter 1 General Information The standard controller must operate in an ambient temperature range of 0 40 C 32 104 F with a relative humidity of up to 95 non condensing Higher ambient temperature conditions are supported with factory assistance The equipment shall be capable of being stored in an environment with an ambient temperature range of 40 85 C 40 185 F If storage temperature fluctuates or if humi
63. nstructions STEP 7 Additional The Extension Elbow Assembly must have additional mounting support Mounting Support 90 Elbow Section Approximate weight 64 kg 142 lbs 36 Extension Assembly Approximate weight 51 kg 112 lbs Figure 88 shows an example of how the Extension Elbow Sections can be supported by suspension from a high ceiling Points A B amp C show where chains or high tension cables may be connected Figure 88 Completed Assembly for optional vertical exit Plenum Right hand exit A B C A A A TIP During an arc fault the plenum will be subjected to a brief high pressure shock wave The Extension Elbow assembly may experience dynamic loading It is important to account for dynamic loading when selecting supporting means and materials 96 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Appendix C ArcShield Chimney Installation Instructions The following instructions are provided to ensure the proper installation and function of chimney supplied with ArcShield enclosures Refer to Appendix A for additional information related to ArcShield chimney before attempting to follow these instructions Recommended Torque 1 4 20 Thread Fasteners 7 5 Nem 6 lbeft Values 5 16 18 Thread Fasteners 14 Nem 11 lbeft Figure 89 Ch
64. nt Enclosure ArcShield If access to the right side of the power bus is required remove the vacuum contactor from the upper power cell refer to Removing the Contactor on page 62 of Chapter 5 Remove the power fuses from the isolation switch Remove the interphase barriers from the trailer fuse block by raising them vertically up and out of the mounting slots see Figure 32 Use a 9 16 in socket to remove the contactor bus bars from the isolation switch trainer fuse block Figure 32 Contactor Bus Bars Trailer Fuse Block for Clip on Fuses Shown Trailer Fuse Block Contactor Bus Bars 10 Disconnect the secondary control wiring from the control power 11 12 transformer CPT and remove the CPT mounting plate Leave the CPT attached to the plate remove and transport the unit Use caution when removing the CPT Failure to do so may result in personal injury and or damage to the equipment ATTENTION The CPT is heavy and assistance may be required to safely To access the right side of the power bus remove the self tapping screws from the lower glass polyester bus access cover and remove the cover see Figure 33 Reverse the procedure to reassemble the cabinet Ensure that the barriers are put back in place 38 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Installation Arc Resistant Enclosure ArcShield Chapter 3 Figure 33 Access to Right Side of Power Bus
65. o lock out incoming power use the appropriate protective equipment and work practices to avoid shock hazards Failure to do so may result in severe burns injury or death f ATTENTION This procedure may expose personnel to energized medium 1 Remove the two 1 4 20 self tapping screws from the Z clip and remove the Z clip Figure 67 Removing Z clip Handle Pin Remove 1 4 20 self tapping screws Remove Z clip 2 Remove the two door locking bolts 3 Use a flat headed screwdriver to turn the defeater pin on the right side of the isolation switch handle see Figure 67 4 Open the power cell door Figure 68 Defeater Pin Defeater Pin Rockwell Automation Publication 1500 UM055H EN P February 2015 77 Chapter5 Maintenance Ifit is possible to move the isolation switch handle to the OFF position for reassembly follow steps 5 10 Ifit is not possible to move the isolation switch handle to the OFF position for reassembly follow steps 11 13 interlocking mechanism functions properly Failure to do so will let personnel access live medium voltage parts and may cause severe burns injury or death i ATTENTION The Z clip assembly must be reassembled to ensure the Installing Z clip with Isolation Switch Handle in the OFF Position 5 Reattach the Z clip using the self tapping screws but do not completely tighten them 6 Move the isolation switch handle to the OFF position 7 Swing the door clos
66. ocked by ice snow or vermin nests e Access barriers are recommended as a means of restricting access by personnel while the equipment is energized Chain link fencing is a suitable barrier material e Equipment that consists of more than 4 vertical sections bolted together may require additional plenum exits Rockwell Automation will provide guidance on requirements for additional plenum exits when required Rockwell Automation Publication 1500 UM055H EN P February 2015 85 AppendixA ArcShield Unit Information Chimney Information A chimney can be provided for each unit and is to be field mounted on top of the unit structure The purpose of the chimney is to direct the hazardous flames and gases away from the top of the resistant enclosure The chimney is secured to the top of each unit structure Refer to Appendix C for chimney installation instructions Each ArcShield line up includes a chimney exhaust section that extends vertically directly above the enclosure Chimney Exhaust Considerations 1 From the outlet of the chimney there needs to be a minimum distance of 1 7 m 67 inches from the top of the chimney to the ceiling and 1 m 39 inches on each side 2 No obstructions eg Piping can be in the path of the exhaust within this 2 m 78 inches height requirement Plan the location where the chimney will exhaust Ensure that e There is no access to personnel while equipment is energized e Area is free of flam
67. omation Publication 1500 UMO55H EN P February 2015 Common Installation Chapter 4 Testing Contactor Operation 1 Connect the appropriate external power supply 120 or 230V AC to the test receptacle in the control panel Turn the selector switch to the TEST position jumpers to let the contactor close during the test procedure Do not jumper any isolation switch contacts such as ISa or Sb see Figure 66 on page 75 for the location of these contacts Using jumpers for these contacts may result in equipment damage or injury to personnel f ATTENTION Some control circuit configurations may require control 2 Electrically operate the contactor several times Inspect the armature plate to verify that it fully contacts the magnetic cores 3 Turn the selector switch to the OFF position and unplug the test voltage 4 Remove any metal filings or loose hardware from around the magnetic cores of the vacuum contactor The debris is attracted to the coil once it is energized and could prevent the contactor from closing properly Rockwell Automation Publication 1500 UM055H EN P February 2015 51 Chapter4 Common Installation Typical Wiring Diagrams Figure 43 Typical Wiring Diagram Electrically Held Vacuum Contactor Relay Control
68. re will make the arc resistance of the cabinet ineffective and could subject personnel to the possibility of severe burns injury or death f ATTENTION Hardware used to retain the lifting provision hardware must be IMPORTANT Do not remove the four corner fasteners Figure 92 Figure 91 Relief Vent Fasteners top view Figure 92 Relief Vent Relief vent ro Corner fasteners Fa o o lo Q Q Q 9 o Relief fasteners 4 The chimneys are designed to fit over the fastener heads at the 4 corners of the Relief vent The corner fasteners are required to secure the Relief vent during installation Rockwell Automation Publication 1500 UM055H EN P February 2015 99 Appendix C 100 ArcShield Chimney Installation Instructions Chimney Placement on Structure Once the Chimney has been lifted in place directly over the relief vent shown in Figure 80 on page 91 all 1 4 20 fasteners removed in Cabinet Preparation on page 99 are replaced to attach the chimney to the top of the enclosure Figure 93 Chimney Placement Use recommended torque value for 1 4 20 fasteners TIP Use silicone caulking generously to fill any air gaps once the chimney has been securely mounted in place Rockwell Automation Publication 1500 UM055H EN P February 2015 Rockwell Automation Support Rockwell Automation provides technical informatio
69. rocedure on page 57 2 Disconnect the control wiring harness from the wire plug at the lower left side of the contactor See Figure 52 3 Remove the control power transformer primary fuses from the top of the contactor 62 Rockwell Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 4 Disconnect the control power transformer primary leads from the fuse terminals at the top of the contactor 5 Use a 9 16 in socket wrench to disconnect the power cables and bus bars from the rear of the contactor 6 Remove the nylon contactor bushing retaining screw from the contactor interlock lever 7 Slide the contactor interlock rod and the nylon contactor bushing out of the groove in the contactor interlock lever see Figure 53 Figure 52 Removing the Contactor Front view Contactor Interlock Rod 0 o A A i uU 0 Oo ontactor Operating Level Figure 53 Removing the Contactor Right side view
70. section Plenum must first be removed This is shown in Figure 77 Figure 77 Removing Front Duct Section Front Duct Section Components N Rockwell Automation Publication 1500 UM055H EN P February 2015 Appendix B ArcShield Plenum Installation Instructions Figure 78 Relief Vent Fasteners top view Relief vent Cabinet Preparation In preparation for mounting Plenum remove the cabinet lifting means slips of lifting angles The bolts retaining the lifting means must be replaced in the holes from where they came Failure to do this will remove the cabinets ability to properly control any arc gases After the lifting angles or clips are removed remove 1 4 20 fasteners from the Relief vent on the top of the MV enclosure reinstalled in the same holes Failure to replace this hardware will make the arc resistance of the cabinet ineffective and could subject personnel to the possibility of severe burns injury or death ATTENTION Hardware used to retain the lifting provision hardware must be IMPORTANT Do not remove the four corner fasteners Figure 79 Figure 79 Relief Vent rE Corner fasteners Fa 5 We o o o o o o Pe o o off o o n ello Ole Q o The Plenums are designed to fit over the fastener heads at the 4 corners of the Relief vent The corner fasteners are required to secure the Relief vent duri
71. see Figure 58 IMPORTANT Lubricate the isolation switch blades a minimum of once per year to avoid excessive wear to the components and to prevent the isolation switch blades from overheating 68 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Maintenance Chapter 5 Figure 58 Isolation Switch Lubrication Points Lubricate Isolation Switch Blades Lubricate Pivot Points Isolation Blade Switch Adjustment before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death i ATTENTION Complete the Power Lockout procedure of the main power bus WARNING Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death 1 Insert a screwdriver in the Isolation Switch Defeater push down and hold at the bottom position 2 Actuate the Isolation Switch Operating Handle from Open black to Closed red in a continuous movement Do not use excessive force or speed in closing the switch This will cause an incorrect test result Rockwell Automation Publication 1500 UM055H EN P February 2015 69 Chapter5 Maintenance Figure 59 Isolation Switch Defeater Closed position Isolation Switch Operating Handle Isolation Switch Defeater Open position 3 Phase 3 far right linkage must be measure
72. should be routed first Pull the cables into the cabinet through the appropriate opening see Figure 18 Run the cables behind the current transformer mounting plate and into the bottom power cell Figure 18 Load Cable Conduit Openings Top Exit Shown f EN Top of Cabinet Load cable Conduit Opening for cables from top power cell Load Cable Conduit opening for cables from bottom power cell Ground Lug 6 For the top power cell pull the cables into the cabinet through the appropriate opening see Figure 18 7 Connect the cables to the current transformers and tighten the connections to 65 Nem 48 Ibeft 8 Connect cable shields to the ground lug 9 Reinstall the cable duct boot and reassemble the cabinet equipment Failure to do so may result in electrical faults and cause ATTENTION Ensure all barriers are replaced before re energizing the damage to equipment or serious injury to personnel Rockwell Automation Publication 1500 UM055H EN P December 2014 27 Chapter2 Installation Standard Enclosure Bottom Exiting Load Cables TIP Follow steps 1 4 from the previous section 5 Load cables for the top power cell should be routed first Pull the cables into the cabinet through the appropriate opening see Figure 19 Run the cables behind the current transformer mounting plate and into the top power cell Figure 19 Load Cable Conduit Openings Bottom Exit Shown wg Load Cabl
73. ss polyester bus access cover and remove the cover see Figure 15 Rockwell Automation Publication 1500 UM055H EN P December 2014 23 Chapter2 Installation Standard Enclosure 17 Reverse the procedure to reassemble the cabinet Ensure that the barriers are put back in place and all parts and tools are accounted for Figure 15 Access to Right Side of Power Bus ADANGER Remove self tapping screws equipment Failure to do so may result in electrical faults and cause damage to f ATTENTION Ensure all barriers are replaced before re energizing the equipment or serious injury to personnel Front Access Bottom Exiting Load Cables If the cables in your cabinet exit from the bottom the procedure to access the power bus is almost identical to the one above Follow the procedure for Top Exiting Load Cables on page 27 but remove the cable duct barrier and cable duct boot from the top of the lower power cell rather than those at the bottom see Figure 16 24 Rockwell Automation Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 Cable Duct Barrier wt a PT Cable Duct Boot Lock out Procedure on page 57 of Chapter 5 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death Load Cable Connections ATTENTION To avoid shock ha
74. stem The leakage current must be less than 20 mA Record the result for future comparison testing Ifa Megger is used it should indicate 50 000 megohms or greater if the unit is isolated from the line and the motor If the unit is connected to a motor the Megger should indicate 5 000 megohms or greater phase to ground Contactor Inspection See Publication 1502 UM050_ EN P or 1502 UM052_EN P for information on pre energization inspection vacuum bottle integrity test and insulation resistance test Preliminary Checks Verify the following e Contactor current and voltage ratings are correct for the attached load e Control voltage is correct e Settings for protective relays e Heater elements if provided in overload relay are secure and undamaged e Equipment grounding e External power and control connections match electrical diagrams e All hardware is correctly reinstalled and torqued to specifications refer to Recommended Torque Values on page 11 of Chapter 1 e All barriers are replaced to correct positions e All fuses are correct class type and rating e Mechanical interlocks and isolation switch function properly e Ensure that any microprocessor based protection relay is programmed e Interior of cabinet is free from dirt loose bolts tools or metal chips Vacuum clean if necessary e All tools are accounted for If you cannot locate a tool do not energize the unit until it is found Rockwell Aut
75. tch handle to the OFF open position 2 Loosen the bolt holding the inside cam to the shaft Do not loosen the bolt entirely The cam should not be able to rotate freely on the shaft 3 Insert a 6 35 mm 0 25 in diameter pin into the cam groove between the cam follower and the end of the cam groove 4 Adjust the cam on the shaft so that the gap from the cam follower to the end of the cam groove is the width of the pin 6 35 mm 0 25 in 5 Tighten the bolt that holds the cam to the shaft Move the isolation switch handle to the OFF position and recheck the gap using the pin Rockwell Automation Publication 1500 UM055H EN P February 2015 75 Chapter5 Maintenance 6 Operate the handle several times then recheck the 6 35 mm 0 25 in clearance between the end of the cam groove and the follower pin for both cams 7 Verify that auxiliary contact ISb is closed when isolation switch is open Verify that ISb contact is open when isolation switch is closed Adjusting the Change of State Point IMPORTANT This procedure sets the secondary electrical interlock When properly adjusted the electrical interlock is designed to open the control power circuit before the isolation switch opens as the handle is moved to the OFF position 1 Once the auxiliaries have been adjusted move the isolation switch handle to the ON position 2 Connect a conductivity measuring device across the closed auxiliary contacts 3 Slowly move th
76. tep 5B Front View 36 in extensions Screen Cover Plate 2 piece 90 elbow section The Extension components are attached to the Elbow Section using 5 16 in Hardware i J Screen Cover Plate Figure 86 illustrates what the xtension Elbow Assembly should resemble when finished 36 in extensions TIP Use silicone caulking generously to fill any air gaps once the Plenum has been securely mounted in place i As referred to in STEP 4 Closing the Front of the Plenum Sections on page 93 STEP 6 Mounting Extension Elbow to Plenum the last Plenum at the exhaust side of the line up has the front duct section 2 Fac B removed This allows access to fastener holes in order to mount the Extension Line u p Elbow components see Figure 87 94 Rockwell Automation Publication 1500 UM055H EN P February 2015 ArcShield Plenum Installation Instructions Appendix B Figure 87 Optional Extension Elbow with Vertical Extension Right side exit Last Plenum in line up remains open for installation of extension assembly o After the Extension Elbow assembly is attached through the fastener holes on the inside flange of the Plenum the front duct section can be replaced and fastened through the holes on the outside flanges Rockwell Automation Publication 1500 UM055H EN P February 2015 95 Appendix B ArcShield Plenum Installation I
77. tments Mounting holes for 1 2 in M12 anchor bolts Mounting holes for 1 2 in M12 anchor bolts required for seismic applications only lt 23 68 601 lt 36 00 914 Minimum distance to concrete floor cut out required for seismic applications T Pi 1 00 25 x 3 00 76 non removable sill channels lt 36 00 914 gt Front All dimensions in mm lt lt 31 38 797 gt NOTES FOR SEISMIC APPLICATIONS e For installations on concrete the minimum depth and radius of concrete supporting the cabinet anchors is dependent on seismic loads Refer to important information above e For installations on a metal structure the metal plate depth and cabinet anchoring method is dependent on seismic loads Joining Sections TIP Joining hardware can be found in a package mounted on the front of the shipping skid Refer to publication MV 0S050_ EN P for level floor surface requirements 1 Position the left side of the section on a level surface and secure the section in place with 12 mm 1 2 in M12 floor mounting bolts refer to Anchoring on page 15 2 When joining NEMA Type 12 apply a continuous 3 mm 1 8 in wide bead of silicone sealer around the perimeter of one section 3 Remove the side bus access covers if applicable 4 Position the right section against the left section Ensure that the surface is level 16 Rockwell Automat
78. tomation Publication 1500 UM055H EN P February 2015 Auxiliary Contacts Inspection and Replacement N WD Wo A N Correct Maintenance Chapter 5 To adjust the distance from the blades to the bar disconnect the threaded connecting rod at the handle operating lever see Figure 57 Turn the threaded connecting rod to lengthen or shorten it This will adjust the position of the isolation switch blades in the ON and OFF position Lock out Procedure on page 57 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTION To avoid shock hazard lock out incoming power refer to Power Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 Inspect the auxiliary contacts for wear scorching or heat damage Replace any damaged contacts The contacts have a mean time between failure MTBE rating of 20 million operations if used within the operating specifications To remove the contact turn both of the D head fasteners until the flat sections are aligned with the edge of the contact see Figure 64 Remove the contact from the housing Disconnect the wires from the auxiliary contact Reverse the procedure to replace the auxiliary contact Ensure the contact is correctly positioned into the contact carrier see Figure 64
79. tor Interlock Rod Adjustment on page 64 Lock out Procedure on page 57 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION To avoid shock hazards lock out incoming power refer to Power Complete the Power Lock out Procedure refer to Power Lock out Procedure on page 57 Open the medium voltage door Use the Door Interlock Circumvention procedure refer to Door Interlock Circumvention on page 56 to move the isolation switch handle halfway between the OFF and ON position see Figure 54 Keep the handle in this position until the adjustment procedure is completed With the contactor in the OFF position insert a 1 5 mm 0 060 in feeler gauge in the gap between the interlock lever and the isolation switch operating lever The gap must be between 1 0 mm to 2 0 mm 0 039 in to 0 078 in To reduce the gap distance follow steps 5 7 To increase the gap distance follow steps 8 10 Rockwell Automation Publication 1500 UMO55H EN P February 2015 Maintenance Chapter 5 Figure 54 Isolation Switch Handle Adjustments Isolation Switch Gap 0 045 0 060 in 1 1 1 5 mm yo Operating Lever Switch Interlock Lever Stop Bracket Isolation Switch Handle at halfway position Contactor Interlock Rod Nyloc Nut Contactor Int
80. ts own isolation switch handle and interlocking safeguards Upper and lower power cells are separated by an isolation barrier Refer to Access to the Power Bus on page 17 for the procedure to open the swing out low voltage panel behind the low voltage door for standard cabinet only 1 Electrically open the contactor by pressing the STOP button on the starter or at the remote control location 2 Move the isolation switch handle to the OFF position 3 Unscrew the door locking bolts for medium voltage door 4 The door is now released and will swing open 14 Rockwell Automation Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 5 Reverse the procedure to close the door IMPORTANT A Ensure that the swing out low voltage panel is in its original position before attempting to close the MV door When closing the medium voltage door ensure all door locking bolts on the right side of the MV door are in place and tightened until the door is flush with the flange Do not overtighten the bolts If the door is not securely fastened it will not be possible to move the isolation switch handle to the ON position ATTENTION Complete the Power Lock out procedure refer to Power Lock out Procedure on page 57 of Chapter 5 before beginning any service procedures to the unit Failure to do so may result in severe burns injury or death Anch oring Place the controller in the desired installation
81. ually Some parts not shown Contactor Interlock Rod N i T o o D Contactor Plug ani i oo A ra l J j Contactor Operating Lever Contactor Mounting Bolts Rockwell Automation Publication 1500 UM055H EN P February 2015 Isolation Switch Mechanism Inspection and Lubrication Maintenance Chapter 5 Figure 56 Isolation Switch Operating Lever Overlap Isolation Switch Operating Lever Overlap minimum 0 125 in 3 mm Interlock Lever 14 Open the contactor Verify that the interlock lever and the rod move freely and that the return springs move the assembly back to the starting position Lock out Procedure on page 57 before working on the equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTIO
82. units The installation section provides instructions for both the standard enclosure type and Rockwell Automation arc resistant type ArcShield The product Bulletin numbers covered by this document are e 1512B 200 400 A FVNR controller e 1512BT 200 400 A Transformer Feeder e 1512BP 200 400A Prepared Space IMPORTANT This document is to be used for all Bulletin 1512B unit types including arc resistant ArcShield units Important information specifically for ArcShield units can be found in Appendix A Appendix B and Appendix C and Appendix C to correctly install and maintain ArcShield arc resistant units Failure to do so may negate the arc resistant benefits provided by ArcShield exposing personnel to risk of serious injury or death ATTENTION Users must refer to the information in Appendix A Appendix B This document may also be used as a reference guide for the following Bulletin numbers e 1512DM 200 400A VFD Input Contactor Units e 1512DO 200 400A VFD Output Contactor units e 1512M 200 400 A VFD Output Bypass Starter e 1562E 200 400 A MV SMC Flex Solid State up to 4800V Reduced Voltage Starter e 1591B Incoming Line Unit e 1592BF Fused Load Break Switch for Feeders e 1592BP Fused Load Break Switch for Feeders prepared space A structure nameplate is attached to the right side flange of the structure see Figure 1 Refer to the nameplate for information such as series number section number NEMA enclosure
83. urn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the OFF position Recommended practice is to disconnect or lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFPA 70E Electrical Safety requirements for Employee Work places must be followed ATTENTION To prevent electrical shock ensure the main power has been disconnected and equipment has been tagged and locked out Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Rockwell Automation Publication 1500 UM055H EN P February 2015 Maintenance Chapter 5 TIP The main power fuse has a pop up indicator pin located at one end of the fuse When a fuse has opened the indicator will be in its extended position The fuse should be oriented in the fuse clip assembly so that the indicator is at the top temperature before handling and use insulated hand protection if needed i ATTENTION The fuses may be hot for up to one hour after operating Verify the Failure to do so may result in burns Bolt on Fuse Removal Installation Tools required 3 8 in drive ratchet 2 in extension 6 in extension 12 in extension 1 2 in socket 3 8 in drive torque wrench TIP Th
84. us flames and gases away from the top of the arc resistant enclosure Unit plenums are secured to the top of the unit structure and to adjacent plenums creating a continuous conduit for release of the arc flash energy Refer to Appendix B for plenum installation instructions Each ArcShield line up includes a plenum exhaust section that extends beyond either the left or right ends of the line up The other end of the plenum is capped with an end cover Extensions can be added to the plenum to allow the arc flash energy to be directed further away from the ArcShield line up to an area where safe venting of the plasma gases can occur Figure 69 Elements of ArcShield Plenum 82 Rockwell Automation Publication 1500 UM055H EN P February 2015 ArcShield Unit Information Appendix A Figure 70 Cross section of Plenum Extension dimensions in inches mm 25 633 Plenum Exhaust Considerations The following options for locating the plenum exhaust are presented 1 Plenum ducted to an area of the control room where arc gases are permitted to escape with plenum extensions see Figure 71 Figure 72 and Figure 73 2 Plenum duct to outside of control room see Figure 71 and Figure 72 Plan the location where the plenum will exhaust Ensure that e There is no access to personnel while equipment is energized e Area is free of flammable material or vapors Ensure that
85. vers and plates removed for installation or maintenance purposes must be re installed and properly secured Failure to do so voids the arc resistance integrity e Power cable entry points are to be treated as the boundary between a hazardous location and sealed accordingly Failure to do so voids the arc resistant integrity e A plenum or chimney must be used to direct the arc flash energy to a suitable location Failure to do so voids the arc resistant integrity Refer to Appendix B for plenum installation instructions Refer to Appendix C for chimney installation instructions e All wiring between the low voltage panel and the power cell must be routed through a suitable gland to ensure flames and gases are not transmitted into this area as fitted from factory e The medium voltage power cell doors must be properly secured using both the handle mechanism and the door bolts refer to instruction label on the power cell door and refer to Opening the Medium Voltage Doors on page 30 of Chapter 3 Failure to do so voids the arc resistance integrity Rockwell Automation Publication 1500 UM055H EN P February 2015 81 AppendixA ArcShield Unit Information Exhaust Systems Chimney or Plenum Information Plenum Option A plenum can be provided for each unit and is to be field mounted on the top of the unit structure some incoming units may not have a plenum if top cable entry is required The purpose of the plenum is to direct the hazardo
86. wever if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852
87. will exhaust refer to Appendix A Equipment in the area of the plenum exhaust will be damaged or destroyed Mark the plenum exhaust area as a Hazardous Zone Figure 74 Figure 74 Plenum Exhaust Label Z DANGER A DANGER AA AM ARC FLASH HAZARD HAZARD D ARC ELECTRIQUE PRESSURE RELIEF EXIT SORTIE DE L EVENT REGION ETRE AREAS TO BE INACCESSIBLE AUX PERSONNEL INACCESSIBLE TO PERSONNEL PENDANT QUE L QUIPEMENT WHILE EQUIPMENT ENERGIZED EST SOUS TENSION FREE OF OBSTRUCTIONS DEMUNI D OBSTRUCTIONS REFER TO USER MANUAL REFERER AU MANUEL SEVERE INJURY OR RISQUE DE BLESSURES DEATH MAY RESULT CORPORELLES GRAVES OU MEME LA MORT Rockwell Automation Publication 1500 UM055H EN P February 2015 87 Appendix Bs ArcShield Plenum Installation Instructions Figure 75 Description of Plenums and Components 18 wide Plenum 26 wide Plenum 36 wide Plenum Fastened directly over the 0 5 m 18 in Fastened directly over the 0 7 m 26 in Fastened directly over the 0 9 m 36 in wide cabinet wide cabinet wide cabinet 18 long Extension 26 long Extension 36 long Extension Connected to the last Plenum on the Connected to the last Plenum on the Connected to the last Plenum on the exhaust end of the line up exhaust end of the line up exhaust end of the line up as cae Screen Cover Plate End Cover Plate 90 Elbow Section Fastened at the opening of the l
88. z PH LV SUPPLY ALIMENTATION BASSE TENSION SHORT CIRCUIT 10 COURT CIRCUIT kA LV1 MAX ALTITUDE m LV2 AMBIENT TEMPERATURE RANGE i GAMME DE TEMPERATURE AMBIANTE c LV3 NOMINAL WEIGHT POIDS NOMINAL kg DATE OF FINAL TEST DATE DE L ESSAI FINAL MMe LV4 EXCITATION SYNCHRONOUS STARTER ONLY DEMARREUR SYNCHRONE SEULEMENT DC VOLTS DC AMPS MOTOR RATING CARACTERISTIQUES ASSIGNE S DU MOTEUR V A Hz PH 3 HP KW RPM S F MADE IN CANADA FABRIQU AU CANADA Refer to these nameplates whenever you contact Rockwell Automation for assistance Be prepared to provide such information as series number structure series unit series diagram schematic and catalog number Rockwell Automation Publication 1500 UM055H EN P February 2015 Prepared Space Recommended Torque Values Environmental Conditions General Information Chapter 1 When ordering a starter kit to complete a prepared space provide the following information to ensure the proper components are supplied Series Number Provide the series number from the structure with the prepared space The number is stamped on a nameplate on the right hand flange of the starter see Figure 1 The series number is also available from the dime
89. zards lock out incoming power refer to Power IMPORTANT The current transformers may be positioned for top or bottom cable exit Follow the appropriate procedure described for your starter configuration IMPORTANT _ Refer to Dimensional Drawings provided with order documentation for additional details 1 Complete the Power Lock out procedure refer to Power Lock out Procedure on page 57 of Chapter 5 2 Open the MV power cell door 3 Remove the cable duct boot at the top of the cabinet for top exiting load cables or remove the one at the bottom of the cabinet for bottom exiting load cables see Figure 17 Rockwell Automation Publication 1500 UM055H EN P December 2014 25 Chapter2 Installation Standard Enclosure Figure 17 Access to Load Cable Conduit Openings Top exit cable configuration shown LV panels removed for clarity Remove Cable Duct Boot to access Load Cable Conduit opening for cables exiting from bottom Power Cell Current Transformer Mounting Plate Connect Load Cables to Current Transformers 4 Remove the appropriate load cable conduit openings in the top or bottom of the cabinet see Figure 18 or Figure 19 TIP Refer to Dimensional Drawings provided with order documentation for additional details 26 Rockwell Automation Publication 1500 UM055H EN P December 2014 Installation Standard Enclosure Chapter 2 Top Exiting Load Cables 5 Load cables for the bottom power cell

1500-UM055_-EN-P - Rockwell Automation

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